Process for producing core yarn

ABSTRACT

This invention relates to a process for the continuous formation of various types of core yarn. Specifically this invention relates to the use of electrostatic, physical and chemical means for producing a core yarn. More specifically, this invention relates to a process for electrostatically, peripherally surfacing or plating a coring element with individual fibers to produce a core yarn. Still more specifically this invention relates to a process for electrostatically, peripherally surfacing or sheathing a coring element with individual fibers and means for treating the coring element with a crosslinking chemical formulation to permanently set the yarn configuration.

United States Patent 11 1 Mayer, Jr. et a1.

PROCESS FOR PRODUCING CORE YARN Inventors: Mayer Mayer, Jr., NewOrleans;

James I.- Kotter; Harold L. Salaun, Jr., both of Metairie; Roger S.Brown, New Orleans, all of La.

-The United States of America as represented by the Secretary ofAgriculture, Washington, DC.

Filed: Mar. 15, 1972 Appl. No.: 235,074

Related US. Application Data Division of Ser. No. 132,953, April 12,1971, Pat. No. 3,696,600.

Assignee:

References Cited UNITED STATES PATENTS 9/1938 Obermaier 57/5 2/1939Radford 1 57/149 7/1940 Dockerty et a1. 57/5 1 Sept. 17, 1974 2,451,88110/1948 Sicgal et a1. 57/5 X 2,841,516 7/1958 Morton 57/162 X 2,997,8378/1961 Brccn et a1. 57/144 X 3,285,690 11/1966 Cooper, Jr. et a1 57/164X 3,382,662 5/1968 Scclig et ul. 57/149 X 3,439,491 4/1969 Scruggs 57/6X 3,696,603 10/1972 Kottcr ct a1 5758.89 3,768,243 10/1973 Brown et a1.57/5 X Primary ExaminerJohn W. Huckcrt Assistant ExaminerCharlesGorenstein [5 7 ABSTRACT This invention relates to a process for thecontinuous formation of various types of core yarn. Specifically thisinvention relates to the use of electrostatic, physical and chemicalmeans for producing a core yarn More specifically, this inventionrelates to a process for electrostatically, peripherally surfacing orplating a coring element with individual fibers to produce a core yarn.Still more specifically this invention relates to a process forelectrostatically, peripherally surfacing or sheathing a coring elementwith individual iibers and means for treating the coring element with acrosslinking chemical formulation to permanently set the yarnconfiguration.

1 Claim, 6 Drawing Figures PATENTEBSEPI'HSH sum 2 or 5 FIGZ sum 3 m5PAIENTED EP 1 1 1914 W 1L N w QQ-H PAIENTEDSE H H Y 3,835,638

SHEEI 4 BF 5 FIG 5 PATENIEU SEP 1 112m sum 5 or 5 PROCESS FOR PRODUCINGCORE YARN This application is a division of Ser. No. 132,953 filed Apr.12, 1971 now US Pat. No. 3,696,600 issued Oct. 10, 1972.

A non-exclusive, irrevocable, royalty-free license in the inventionherein hescribed, throughout the world for all purposes of the UnitedStates Government, with the power to grant sublicenses for suchpurposes, is hereby granted to the Government of the United States ofAmerica.

It is well known to those skilled in the'artthat present methods ofproducing a core yarn are limited to the process of twisting a surfacingyarn around the coring element. Prior to the disclosure of the instantinvention, it was common to the art to produce core yarns either onspinning frames or on twisters. The art also frequently makes use oftexturizing means to obtain desired yarn types.

The main object of our invention is to provide a process to produce coretype yarns by a unique and novel method.

A second object of our invention is to provide a process to produce acore yarn with a bulk appearance.

Another object of our invention is to provide a process to produce acore yarn by the method of electrostatically surfacing fibersperipherally onto a coring element.

Another object of our invention is to provide a process to produce acore yarn by the method of electrostatically surfacing and mechanicallyattaching peripheral fibers permanently onto a coring element.

Still another object of our invention is to provide a process to producea core yarn by the method of electrostatically surfacing fibersperipherally onto a coring element which has been treated with acrosslinking resin and subsequently curing to produce a permanent yarnconfiguration.

Still another object of our invention is to provide a process forproducing a core yarn by the method of electrostatically plating fibersperipherally onto a coring element of a thermosetting material andsubsequently applying heat to permanently adhere the plating fibers tothe core.

These and additional objects and advantages of our invention will beapparent from the following drawings, dpecifications, and claims setforth herein.

FIG. 1 is a schematic view of a process for electrostatically producinga core yarn.

FIG. 2 is a pictorial view of one embodiment of a twisting element.

FIG. 3 is a pictorial view of a second embodiment of a twisting element.

FIG. 4 is a schematic view of a second embodiment of a process forelectrostatically, chemically and physically producing a core yarn.

FIG. 5 is a schematic view of another embodiment of a process forelectrostatically and physically producing a core yarn.

FIG. 6 illustrates the modified apparatus of copending patentapplication Ser. No. 132,953 filed Apr. 12, 1971.

Referring to our drawings, FIG. 1 is the embodiment of our inventionshowing any type power supply such as supply 10 capable of, for example,up to 120 kv at 2 milliamps which is connected by leads 11 and 12 to theelectrodes 13 and 14 of electrostatic fiber collecting and yarn spinningapparatus 15 of copending Patent Application,-Ser. No. 132,953 filedApr. 12, 1971. A coring element 16 of any type staple fiber or filamentof supply package 17 on spindle 18 is rotatably mounted on anyconventional braking mean such as friction brake 19. Coring element 16is fed past rotatably mounted guide roll 20 in bearings not shown intoelectrostatic fiber collecting and yarn spinning apparatus 15. Saidelement 16 passes through axis of rotation of electrode 14 of unit 15.It is to be understood that conical electrode and twisting element ofunit 15 of copending Patent Application Ser. No. 132,953 filed Apr. 12,1971 is to be modified by relocation of drive to permit coring element16 to pass through center of rotation of conical electrode and twistingelement. Individual fibers 21 from any conventional source not shown arefed from duct 22 into the electric field 23 of unit 15. Said fibers 21migrate to region of highest field intensity which is also region ofclosest proximity of electrodes l3 and 14 of unit 15. Individual fibers21 contact the twisting element 24 of unit 15 and because of therotation of electrode 14 and twisting element 24, said fibers 21 twistaround coring element 16 and completely and uniformly cover theperipheral surface of said coring element 16 to produce a uniform coreyarn 25. Said core yarn 25 passes rotatably mounted guide rolls 26 and27 in bearing not shown and wound on any type package common to the artsuch as cone 28. Said cone 28 is driven by any conventional variablespeed drive such as variable speed motor 29.

Another embodiment of invention uses a twisted coring element 16 fed totwisting element 24 such that rotation of said twisting element 24 willeffect a false untwist to partially or completely untwist coring element16 prior to attachment of peripheral surface fibers 21 Once falseuntwist is released, the normal twist of coring element 16 will tightlyhold said surface fibers 21, due to interlocking of the fibers withinthe coring element, to produce a permanent core yarn 25 having saidfibers interlocked within the coring element. Twisting element 24 ofunit 15, FIG. 1, may be of any desired shape to produce any specificcore yarn configuration. Referring to FIG. 2, essentially round twistingelement 40 with a longitudinal hole 41 along axis and any type smoothconvexed surface at discharge end 42 will produce a core yarn with abulked appearance resembling an angora wool yarn.

Another embodiment, FIG. 3, of twisting element 45 is cylindrical inshape with an entrance hole 46 on axis of element 45. Said hole 46follows a smooth angular path terminating at 47 at periphery of element45. Discharge end of element follows a reverse configuration toentrance. Hole 48 starts at periphery of element 45 180 opposite toopening 47 and proceeds angularly toward center discharge post 49. Coreyarn made with said element 45 will produce a core yarn with a smoothuniform peripheral surface of fibers on the coring yarn.

Other designs of twisting elements to produce specific core yarnconfigurations will be obvious to those skilled in the art.

Another embodiment of our invention to produce permanent type coreelement is shown in FIG. 4. A coring yam 50 from supply package 51 onspindle 52 rotatably mounted on any type braking means such as frictionbrake 53, passes rotatably mounted guide rolls 54, 55, and 56 inbearings not shown. Said coring element 50 enters any type treatingvessel such as tank 57,

containing any desired crosslinking agent 58 such as 5 percent topercent dimethylol ethyleneurea (DMEU) or dimethyloldehydroxyethyleneurea (DMDHEU) and is maintained at a relativelyconstant temperature and volume by conventional methods not shown.Coring element is held immersed in crosslinking resin 58 by rotatablymounted immersion roll 59 inbearings not shown. Element 50 proceeds overrotatable squeeze rolls 60 and 61 in bearings not shown to remove excesssolution. Roll 60 is positively driven by any conventional variablespeed drive such as variable speed motor 62, pulleys 63 and 64 and belt65. Roll 61 is weighted by any conventional means such as coil spring66. Element 50 with crosslinking resin enters electrostatic fibercollecting and yarn spinning apparatus 67 of copending PatentApplication Ser. No. 132,953 filed Apr. 12, 1971. Individualized fibersfrom any conventional source not shown are fed into unit 67 by duct 68.Peripheral fiber surfacing onto coring element 50 is accomplished withinunit 67 in same manner as described in embodiment, FIG. 1. Core yarn 69from unit 67 proceeds over rotatably mounted guide roll 70 in bearingsnot shown to any type curing stage common to the art such as radiantheater 71 wherein the resintreated core yarn 69 is cured and set. Thiscuring of the resin permanently sets the peripheral fibers to the coringelement so that it can be knitted, woven, and otherwise handled withoutlosing its configuration and characteristics. The core yarn 69 passesthrough rotatable mounted guide rolls 72 and 73 in bearings not shownand is wound on any type package such as cone 74 which is driven by anyvariable speed means common to the art such as variable speed motor 75.Motors 62 and 75 are synchronously controlled by output of conventionalcontrol 76 through leads 77 and 78.

In addition to providing the resin formulation for permanently fixingthe core yarn 69, tank 57 can contain other chemicals to impart otherdesirable properties. For example, bath 58 can be formulated to containdimethylol ethyleneurea (DMEU) for permanent setting, carboxymethylcellulose for antisoiling, copper naphthenate for mildew proofing oftetrakis (hydroxy methyl) phosphonium chloride for flame resistance.Other possibilities for multipurpose treatment will be obvious to thoseskilled in the art of textile finishing.

In another embodiment of our invention, FIG. 5, coring element isconstructed of any type thermosetting material common to the art such asa nylon filament. Said coring element 100 from supply package 101 onspindle 102 mounted on any type braking means such as friction brake 103is fed past rotatably mounted guide roll 104 in bearings not shown intoelectrostatic fiber collecting and yarn spinning apparatus 105 ofcopending Patent Application Ser. No. 132,953 filed Apr. 12, 197 l.Individualized fibers from any conventional source not shown are fedinto unit 105 from duct 106. Peripheral fiber surfacing onto coringelement 100 is accomplished within unit 105 in same manner as describedin embodiment, FIG. 1. Core yarn 107 from unit 105 proceeds overrotatably mounted guide roll 108 in bearings not shown to any typesetting stage common to the art such as radiant heater 109 wherein theperipheral fibers are permanently set onto the coring element 100. Thecore yarn 107 passes through rotatably mounted guide rolls 110 and 111in bearings not shown and is wound on any type package such as cone 112which is driven by any variable speed means common to the art such asvariable speed motor 113.

Referring to FIG. 6, the apparatus is comprised of conic electrode 14,rotatably mounted, axially and radially supported by hollow spindle 114through bearings 115 and 116. Hollow spindle 114 is independently drivenby variable speed motor 117, through motor shaft 118, pulleys 119 and146 and nonconducting belt 120. Motor 117 is connected to and supportedby sup port member 135. Hollow spindle 114 is also rotatably mounted,independently driven by any type driving means such as highspeed motor121, through motor shaft 123, pulleys 122 and 147 and nonconducting belt133. Hollow spindle 114 is axially and radially supported bynonconducting support member 137 through bearing 136. Motor 121 isconnected to and supported by support member 138.

Conic electrode 14 is supported by means of protruding bearing surfaces124 and 125 of hollow spindle 114. Conic electrode 14 is energized, forexample, by a standard DC power supply with 10 kilovolts to 60 kilovoltsat 2 milliamperes maximum current through conventional wire and slidecontacting means.

Hollow spindle 114 is constructed with a conducting cylindrically shapedknife-edge ring 126, extending axially there-through opening 127 andterminating slightly above surface of conic electrode 14.

Attached to and extending axially from hollow spindie 1 14 is a hollownonconducting twisting element 24.

Referring to FIGS. 1 and 6: to provide an adequate electrostatic fieldfor complete removal of individual fibers 21, from the airstream, flatplate electrode 13 is constructed sufficiently large to extend beyondperiphery of conic electrode 14, and flat plate electrode 13 is providedwith opening 29 extending there-through axially aligned with hollowtwisting element 24. Flat-plate electrode 13 is adjustably mounted bymeans of movable clamp 142 (in partial view) and it is electricallygrounded through conventional wire and standard connections.

Coring element 16 is guided into hollow spindle 114 by guide roll 20,which is rotatably mounted onto stubshaft 143, by means of bearing 144.Stubshaft 143 is attached to support members 145. Coring element 16passes through center of rotation of hollow spindle 114 and hollowtwisting element 24. As coring element 16 leaves hollow twisting element24, fibers 21 are spun there-around, mechanically bonding said fibers 21to said element 16, forming core yarn 25. The coring element 16encapsulated with spun fibers 21 in the electrostatic field 23, emergingas core yarn 25, passes through opening 29 of stationary flat plateelectrode 13 through guide rolls 26 and 27 to winding means such as cone28 attached to motor 29.

Other spindle element configuration and variations thereof may besuccessfully utilized, for example a conic fiber twisting component witha centrally located circular passage beginning at its base, extendingtherethrough and terminating axially at its apex.

Although all embodiments of this invention have been discussed in termsof producing core yarn on a coring element it is also understood that itis feasible to produce core yarn from other coring textile strands suchas roving.

We claim:

1. A mechanically locked core yarn with peripherally spun fibers about acoring element, said fibers tightly held by the coring element andinterlocked therewith, said interlocking effected by feeding a twistedcoring 6 tially untwist said coring element, attaching said peripheralfibers, releasing said false untwist to cause the normal twist of saidcoring element to tightly hold and element to a twisting element,rotating said twisting eleinterlock with Said Peripheral fibersment in adirection to effect a false twist to at least par-

1. A mechanically locked core yarn with peripherally spun fibers about acoring element, said fibers tightly held by the coring element andinterlocked therewith, said interlocking effected by feeding a twistedcoring element to a twisting element, rotating said twisting element ina direction to effect a false twist to at least partially untwist saidcoring element, attaching said peripheral fibers, releasing said falseuntwist to cause the normal twist of said coring element to tightly holdand interlock with said peripheral fibers.